Fluorescent Dye Leak Detection
FLUORESCENT DYE LEAK DETECTION
Fluorescent Dye Injection - Using an R-134a Refrigerant Management Center and Dye/Lubricant Injector (Non-Hybrid Only)
CAUTION:Do not add liquid-based R-134a Leak Detection Dye to the refrigerant system on hybrid vehicles equipped with an electric Air Conditioning (A/C) compressor. Liquid-based dyes are mixed with PAG oil, and will contaminate and damage the hybrid refrigerant system. Dye can only be added to hybrid vehicles by installing a new receiver/drier which includes a fluorescent dye "wafer" which will dissolve after approximately 30 minutes of continued A/C operation.
NOTE:Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.
NOTE:This method of fluorescent dye injection requires the addition of R-134a from a R-134a Refrigerant Management Machine or R-134a Manifold Gauge Set hooked to an external tank to charge the dye into the refrigerant system. If adding fluorescent dye to a refrigerant system that is already fully charged, the R-134a Loop/Add On Injector Kit-Set method should be used.
NOTE:Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the manufacturer's instructions on evacuation of any non-condensable gases from the hoses.
NOTE:Only connect the dye/lubricant injector from the R-134a Loop/Add On Injector Kit-Set when fluorescent dye is to be injected. The dye/lubricant injector has a one-way check valve that will prevent refrigerant system recovery and evacuation.
NOTE:Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off.
NOTE:If no R-134a pressure is present in the refrigerant system, the system should be evacuated before carrying out the injection procedure. See Air Conditioning (A/C) System Evacuation And Charging.
1. Connect a R-134a Refrigerant Center or a R-134a Manifold Gauge set to the refrigerant system service port valves.
NOTE:The dye/lubricant injector is included as part of the 219-00069 R-134a Loop/Add On Injector Kit-Set.
2. Verify that the valves on the dye/lubricant injector are closed.
3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye.
4. Install the dye/lubricant injector between the low-pressure service gauge port valve and the R-134a Refrigerant Center or R-134a Manifold Gauge Set.
5. Open all valves and inject the fluorescent dye into the refrigerant system.
6. When fluorescent dye injection is complete, close all valves.
7. Recover the refrigerant from the dye/lubricant injector.
8. Remove the dye/lubricant injector from the low-pressure service gauge port valve and the R-134a Refrigerant Center or R-134a Manifold Gauge Set.
Fluorescent Dye Injection - Using an R-134a Loop/Add On Injector Kit-Set (Non-Hybrid Only)
CAUTION:Do not add liquid-based R-134a Leak Detection Dye to the refrigerant system on hybrid vehicles equipped with an electric Air Conditioning (A/C) compressor. Liquid-based dyes are mixed with PAG oil, and will contaminate and damage the hybrid refrigerant system. Dye can only be added to hybrid vehicles by installing a new receiver/drier which includes a fluorescent dye "wafer" which will dissolve after approximately 30 minutes of continued A/C operation.
NOTE:Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved UV blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.
NOTE:Before using the R-134a Loop/Add On Injector Kit-Set for the first time, refer to the manufacturer's instructions on evacuation of non-condensable gases from the hoses.
NOTE:Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off and cool.
1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the R-134a Loop/Add On Injector Kit-Set reservoir with 7 ml (0.25 oz) of fluorescent dye.
3. Install the R-134a Loop/Add On Injector Kit-Set between the high-pressure and low-pressure service gauge port valves.
CAUTION:Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine.
4. Start the engine.
5. Set the A/C to the ON position.
6. Open the high pressure service valve.
NOTE:To prevent pressure spike/liquid slug, crack the R-134a Loop/Add On Injector Kit-Set valves and slowly open to inject the fluorescent dye into the refrigerant system.
7. Open the R-134a Loop/Add On Injector Kit-Set valves and inject the fluorescent dye into the refrigerant system.
8. Close the high-pressure service valve to allow the pressure inside the R-134a Loop/Add On Injector Kit-Set to equalize with the suction side of the refrigerant system.
NOTE:Close the valves on the R-134a Loop/Add On Injector Kit-Set while the A/C compressor is operating.
9. Close the valves on the R-134a Loop/Add On Injector Kit-Set.
NOTE:Leave all valves on the R-134a Loop/Add On Injector Kit-Set closed when not in use.
10. Disconnect the high-pressure and low-pressure service valves and remove the R-134a Loop/Add On Injector Kit-Set from the vehicle.
Fluorescent Dye Detection
NOTE:Mazda Corporation vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak.
1. Check for leaks using a Rotunda-approved UV lamp.
- Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. See Air Conditioning (A/C) System Discharging And Recovery.
3. Repair the refrigerant system leak(s).
4. Evacuate the charge the refrigerant system. See Air Conditioning (A/C) System Evacuation And Charging.
5. After the leak(s) is repaired, remove any traces of fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp.